Please read these Operational Instructions carefully and follow them accordingly! Ignoring these Instructions may lead to malfunctions or to brake failure, resulting in damage to other parts. These Installation and Operational Instructions (I + O) are part of the brake delivery. Please keep them handy and near to the brake at all times. Contents: Safety and Guideline Signs... 2 General Guidelines... 3 Guidelines for Electromagnetic Compatibility (EMC)... 3 Application Conditions... 3 Dimensioning... 3 Climate Conditions... 4 Intended Use... 4 Earthing Connection... 4 Class of Insulation F (+155 C)... 4 Protection... 4 Brake Storage... 4 Handling... 4 User-implemented Protective Measures:... 4 Standards, Directives and Regulations Used... 5 Liability... 5 Guarantee... 5 CE Identification... 5 Conformity Markings... 5 Identification... 5 Definition of the Braking Torques... 6 Static braking torque... 6 Dynamic braking torque... 6 Run-in procedure / Conditioning of the friction lining pairing... 6 Parts List... 7 Technical Data (Independent of Size)... 7 Table 1: Technical Data (Dependent on Size)... 8 Table 2: Technical data (dependent on size)... 8 Table 3: Technical data (dependent on size)... 8 Table 4: Technical data (dependent on size)... 9 Table 5: Technical data (dependent on size)... 9 Table 6: Technical Data (Dependent on Size)... 10 Table 7: Technical data (dependent on size)... 10 Design... 10 Function... 10 Scope of Delivery / State of Delivery... 10 Installation Conditions... 11 Run-in Procedure... 11 Installation (Figs. 1 and 2)... 11 Braking torque adjustment... 12 Brake Inspection (before brake initial operation)... 12 Hand Release Installation (see Figs. 1 and 5)... 12 Switching Times... 13 Table 8: Switching times... 13 Electrical Connection and Wiring... 14 Magnetic Field Removal... 15 Permitted Brake Friction Work... 16 Friction Power Diagram 1 for 891.01_._ and 891.21_._ (Standard brake) at reference speed n ref... 16 Friction Power Diagram 2 for 891.01_._ and 891.21_._ (Standard brake) at Maximum speed n max... 16 Friction Power Diagram 3 for 891.10_._ (Holding brake) at reference speed n ref... 17 Friction Power Diagram 4 for 891.10_._ (Holding brake) at Maximum speed n max... 17 Air Gap Inspection (only Size 500)... 18 Maintenance... 18 Replacing the Rotor (4):... 19 Information on the Components... 19 Cleaning the Brake... 19 Disposal... 19 Malfunctions / Breakdowns... 20 Malfunctions / Breakdowns... 21, Germany Page 1 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Safety and Guideline Signs DANGER Immediate and impending danger which can lead to severe physical injuries or to death. WARNING Possibly dangerous situation, which can lead to severe physical injuries or to death. CAUTION Danger of injury to personnel and damage to machines. Please Observe! Guidelines on important points. Guidelines on the Declaration of Conformity A conformity evaluation has been carried out for the product (electromagnetic safety brake) in terms of the EU Low Voltage Directive 2014/35/EU. The Declaration of Conformity is laid out in writing in a separate document and can be requested if required. Guidelines on the EMC Directive (2014/30/EU) The product cannot be operated independently according to the EMC directive. Due to their passive state, brakes are also non-critical equipment according to the EMC. Only after integration of the product into an overall system can this be evaluated in terms of the EMC. For electronic equipment, the evaluation has been verified for the individual product in laboratory conditions, but not in the overall system. Guidelines on the Machinery Directive (2006/42/EC) The product is a component for installation into machines according to the Machinery Directive 2006/42/EC. The brakes can fulfil the specifications for safety-related applications in coordination with other elements. The type and scope of the required measures result from the machine risk analysis. The brake then becomes a machine component and the machine manufacturer assesses the conformity of the safety device to the directive. It is forbidden to start use of the product until you have ensured that the machine accords with the regulations stated in the directive. Guidelines on the EU Directive on the Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic Equipment The electromagnetic brake as well as the rectifiers / microswitches / proximity switches required for control / self-monitoring fulfil the requirements laid down in the EU Directive 2011/65/EC (RoHS). (Restrictions on the use of certain hazardous substances, such as lead (0.1 %), mercury (0.1 %), cadmium (0.01 %), hexavelent chromium (0.1 %), polybrominated biphenyls (PBB) (0.1 %), polybrominated diphenylethers (PBDE) (0.1 %)) Guidelines on the ATEX Directive Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion. For application of this product in areas where there is a high danger of explosion, it must be classified and marked according to Directive 2014/34/EU. Page 2 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Safety Regulations These Safety Regulations are user hints only and may not be complete! General Guidelines DANGER Danger of death! Do not touch voltagecarrying lines and components. Brakes may generate further risks, among other things: Hand injuries Danger of seizure Contact with hot surfaces Magnetic fields Severe injury to people and damage to objects may result if: the electromagnetic brake is used incorrectly. the electromagnetic brake is modified. the relevant standards for safety and / or installation conditions are ignored. During the risk assessment required when designing the machine or system, the dangers involved must be evaluated and removed by taking appropriate protective measures. To prevent injury or damage, only professionals and specialists are allowed to work on the devices. They must be familiar with the dimensioning, transport, installation, initial operation, maintenance and disposal according to the relevant standards and regulations. Before product installation and initial operation, please read the Installation and Operational Instructions carefully and observe the Safety Regulations. Incorrect operation can cause injury or damage. At the time these Installation and Operational Instructions go to print, the electromagnetic brakes accord with the known technical specifications and are operationally safe at the time of delivery. limit values. For this reason it is important to read the Installation and Operational Instructions very carefully and to keep to the EMC Directives. Application Conditions The catalogue values are guideline values which have been determined in test facilities. It may be necessary to carry out your own tests for the intended application. When dimensioning the brakes, please remember that installation situations, braking torque fluctuations, permitted friction work, run-in behaviour and wear as well as general ambient conditions can all affect the given values. These factors should therefore be carefully assessed, and alignments made accordingly. Mounting dimensions and connection dimensions must be adjusted according to the size of the brake at the place of installation. The magnetic coils are designed for a relative duty cycle of 100%. The braking torque is dependent on the present run-in condition of the brake. The brakes are only designed for dry running. The torque is lost if the friction surfaces come into contact with oil, grease, water or similar substances or foreign bodies. The surfaces of the outer components have been phosphated manufacturer-side to form a basic corrosion protection. CAUTION The rotors may rust up and block in corrosive ambient conditions and/or after long periods of storage. The user is responsible for taking appropriate countermeasures. Technical data and specifications ( tags and documentation) must be followed. The correct connection voltage must be connected according to the tag and wiring guidelines. Check electrical components for signs of damage before putting them into operation. Never bring them into contact with water or other fluids. Please observe the EN 60204-1 requirements for electrical connection when using in machines. Only carry out installation, maintenance and repairs in a de-energised, disengaged state and secure the system against inadvertent switch-on. Dimensioning Attention! When dimensioning the brake, please take into consideration whether a load torque is present when selecting the protection. Load torques reduce the deceleration torque available. Load torques may increase the output speed: during a possible processing time in the controls during the brake downtime When calculating the friction work, please observe that the brake nominal torque is subject to a tolerance. Guidelines for Electromagnetic Compatibility (EMC) In accordance with the EMC directives 2004/108/EC, the individual components produce no emissions. However, functional components e.g. mains-side energisation of the brakes with rectifiers, phase demodulators, ROBA -switch devices or similar controls can produce disturbance which lies above the allowed Page 3 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Safety Regulations These Safety Regulations are user hints only and may not be complete! Climate Conditions The ROBA-stop -M is suitable for applications with an ambient temperature of between -20 C and +40 C. CAUTION CAUTION Reduction in braking torque possible Condensation can form on the brake and cause a loss in braking torque: due to fast changes in temperature at temperatures of around or under freezing point The user is responsible for taking appropriate countermeasures (e.g. forced convection, heating, drain screw). Brake malfunction possible Condensation can form on the brake and cause malfunctions: at temperatures around or under freezing point, the brake can freeze over and not release any more. The user is responsible for taking appropriate countermeasures (e.g. forced convection, heating, drain screw). The system function must be checked by the user after longer downtimes. at high temperatures and in high humidity or with occurring dampness, the rotor can seize up to the armature disk or the bearing shield / the flange plate after longer downtimes. Intended Use mayr -brakes have been developed, manufactured and tested in compliance with the DIN VDE 0580 standard and in accordance with the EU Low Voltage Directive as electromagnetic components. During installation, operation and maintenance of the product, the requirements for the standard must be observed. mayr -brakes are for use in machines and systems and must only be used in the situations for which they are ordered and confirmed. Using them for any other purpose is not allowed. Earthing Connection The brake is designed for Protection Class I. This protection covers not only the basic insulation, but also the connection of all conductive parts to the protective conductor (PE) on the fixed installation. If the basic insulation fails, no contact voltage will remain. Please carry out a standardised inspection of the protective conductor connections to all contactable metal parts! Class of Insulation F (+155 C) The insulation components on the magnetic coils are manufactured at least to class of insulation F (+155 C). Brake Storage Store the brakes in a horizontal position, in dry rooms and dust and vibration-free. Relative air humidity < 50 %. Temperature without major fluctuations within a range from 20 C up to +60 C. Do not store in direct sunlight or UV light. Do not store aggressive, corrosive substances (solvents / acids / lyes / salts / oils / etc.) near to the brakes. For longer storage of more than 2 years, special measures are required (please contact the manufacturer). Storage acc. DIN EN 60721-3-1 (including the limitations / additions described above): 1K3; 1Z1; 1B1; 1C2; 1S3; 1M1 Handling Before installation, the brake must be inspected and found to be in proper condition. The brake function must be inspected both once attachment has taken place as well as after longer system downtimes, in order to prevent the drive starting up against possibly seized linings. User-implemented Protective Measures: Please cover moving parts to protect against injury through seizure. Place a cover on the magnetic part to protect against injury through high temperatures. Protection circuit: When using DC-side switching, the coil must be protected by a suitable protection circuit according to VDE 0580, which is integrated in mayr -rectifiers. To protect the switching contact from consumption when using DC-side switching, additional protective measures may be necessary (e.g. series connection of switching contacts). The switching contacts used should have a minimum contact opening of 3 mm and should be suitable for inductive load switching. Please make sure on selection that the rated voltage and the rated operating current are sufficient. Depending on the application, the switching contact can also be protected by other protection circuits (e.g. mayr - spark quenching unit, half-wave and bridge rectifiers), although this may of course then alter the switching times. Install additional protective measures against corrosion if the brake is subject to extreme ambient conditions or is installed in open air conditions, unprotected from the weather. Take precautions against freeze-up of the friction surfaces in high humidity and at low temperatures. Protection IP54: When installed, dust-proof and protected against contact as well as against water spray from any direction (dependent on customer-side mounting method). IP66 ( 891. 4.1): Dust-proof and protected against contact as well as against strong jet water from a nozzle coming from any direction. Page 4 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Safety Regulations These Safety Regulations are user hints only and may not be complete! Standards, Directives and Regulations Used DIN VDE 0580 2014/35/EU Electromagnetic devices and components, general specifications Low Voltage Directive CSA C22.2 No. 14-2010 Industrial Control Equipment UL 508 (Edition 17) EN ISO 12100 DIN EN 61000-6-4 DIN EN 61000-6-2 Industrial Control Equipment Safety of machinery General principles for design - Risk assessment and risk reduction Interference emission Interference immunity Liability The information, guidelines and technical data in these documents were up to date at the time of printing. Demands on previously delivered brakes are not valid. Liability for damage and operational malfunctions will not be taken if: - the Installation and Operational Instructions are ignored or neglected. - the brakes are used inappropriately. - the brakes are modified. - the brakes are worked on unprofessionally. - the brakes are handled or operated incorrectly. Guarantee The guarantee conditions correspond with the Chr. Mayr GmbH + Co. KG sales and delivery conditions. Mistakes or deficiencies are to be reported to mayr at once! CE Identification according to the Low Voltage Directive 2014/35/EU Conformity Markings in terms of the Canadian and American approval Identification mayr components are clearly marked and described on the tag: Product name Serial number Article number Approval number (if available) C US CE marking Size/ Voltage Power Braking torque DataMatrix code only for voltages > 72 V (CE identification with ID number of the respective inspection authority, only for type examination tested brakes) Page 5 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Safety-relevant Applications Brakes which are used in safety-related applications are to be selected in accordance with the risk assessment EN ISO 12100 and furthermore in accordance with EN ISO 13849-1 through identification of the safety function. This is in principle the task of the system manufacturer. Roba-stop -M standard designs with safety parameters: 891.10_._ Nominal torque holding brake 891.01_._ 891.02_._ 891.03_._ 891.07_._ 891.08_._ Safety parameters can be requested if required. In case of deviating designs, please consult with mayr power transmission directly. Definition of the Braking Torques Static braking torque Effectively averaged, fully developed torque at slipping brake with smallest speed values. Guideline value: n = 3 [1/min] Dynamic braking torque Effectively averaged, fully developed torque in a braking procedure from the output speed up to standstill. For correct evaluation, a sufficient slip time is required (sliding speed between 1 m/s and 10 m/s). The permitted friction work and speed values must not be exceeded. Run-in procedure / Conditioning of the friction lining pairing The stated brake nominal torques are valid for a run-in / conditioned state of the friction lining pairing in standard climate conditions. Conditioning of the friction lining pairing Conditioning is necessary Please carry out conditioning of the friction lining pairing through dynamic braking procedures of the system. in new condition during the operation of the system Recommendation: Approx. Please carry out approx. 5 dynamic braking procedures at 50 % of the permitted speed n max at 25 % of the permitted friction work Q r zul. A generally valid definition of the parameters required for the conditioning is not possible due to the different application possibilities. The frequency of the friction lining pairing conditioning and the torque inspection must be determined by the user depending on the application. Dimension with a correspondingly higher safety Regular conditioning is not possible EMERGENCY STOP Recommendation: Si 2.0 Please observe: The dynamic dimensioning must be taken into account separately After brake run-in procedure! Page 6 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
F α 15 3 16 8 26 Air gap a 11 9 25 24 23 4 7 12 1 2 14 10 13 5 Cable length Standard approx.. 400 mm on sizes 2-60 and approx.. 600 mm on sizes 100-500 6 Fig. 1 Fig. 2 Fig. 3 Fig. 4 Parts List (Only use mayr original parts) 1 Hub 14 Sealing plug (only for Sizes 8 to 500) 2 Coil carrier with magnetic coil (7) 15 Hand release rod 3 Armature disk 16 Switch bracket 4 Rotor 17 Threaded bolt (see page 12, Fig. 5) 5 Friction disk 18 Thrust spring (hand release; see page 12, Fig. 5) 6 Thrust spring (torque) 19 Hexagon nut (see page 12, Fig. 5) 7 Magnetic coil 20 Washer (see page 12, Fig. 5) 8 Cap screw 21 O-ring (see page 12, Fig. 5) 9 Flat sealing ring ( 891. _.1) 22 Intermediate plate (see page 12, Fig. 5) 10 Shoulder screw (not shown) 23 Adjusting screw (central torque adjustment) 11 O-ring ( 891. _.1) 24 Parallel pin (central torque adjustment) 12 Flange plate sealed ( 891. _.1) 25 Thrust spring (central torque adjustment) 13 Flange plate tacho brake 26 tag Technical Data (Independent of Size) Nominal voltages: Protection: Protection ( 891. _.1): 24 V/104 V/180 V/207 V IP54 IP66 Duty cycle: max. 100 % Ambient temperature: -20 C up to +40 C Page 7 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Table 1: Technical Data (Dependent on Size) Size Standard brake 891._ 1_. _ Idle speed Maximum speed Nominal torque M2 n max Holding brake 891.10 _. _ Idle speed Maximum speed Nominal torque M2 n max Reference speed n ref Electrical nominal power P N Electrical Connection Cross-section [Nm] [rpm] [Nm] [rpm] [rpm] [W] [mm2] [kg] 2 2 6000 9000 4 6000 9000 6000 19 2 x 0.56 0.76 4 4 5000 8800 8 5000 9000 5000 25 2 x 0.56 1.1 8 8 4000 7000 16 4000 9000 4000 29 2 x 0.56 1.8 16 16 3500 5600 32 3500 9000 3000 38 2 x 0.88 3.4 32 32 3000 4700 64 3000 7800 1500 46 2 x 0.88 4.5 60 60 3000 7200 100 3000 7300 1500 69 2 x 0.88 7.4 100 100 3000 6200 180 3000 6200 1500 88 2 x 0.88 13.6 150 150 4200 5400 280 3000 5400 750 98 2 x 0.88 19.2 250 250 3600 4700 460 2500 4700 750 120 2 x 0.88 33.3 500 500 3000 3800 900 1) 2000 3800 750 152 2 x 0.88 38 1) Brake operation only possible with overexcitation. Table 2: Technical data (dependent on size) Nominal air gap "a" +0.1 / -0.05 Maximum permitted air gap "a" after wear Mass without flange plate, without hand release Inspection dimension "x" Numberof turns "Y" on the hexagon nuts (19) Design without flange plate Fixing screw Item 8 (Fig. 1) Design with flange plate Tightening torque (Fig. 2) (Fig. 2) (Fig. 5) (Fig. 5) (Item 12/13) DIN (Item 12/13) DIN Size [mm] [mm] [mm] EN ISO EN ISO [Nm] 2 0.15 0.4 0.9 +0.1 1.7 3 x M4 x 45 4762 3 x M4 x 50 4762 2.5 4 0.15 0.4 0.9 +0.1 1.7 3 x M4 x 45 4762 3 x M4 x 50 4762 2.5 8 0.2 0.45 1.1 +0.1 1.5 3 x M5 x 50 4762 3 x M5 x 55 4762 5.0 16 0.2 0.7 1.6 +0.1 2.0 3 x M6 x 60 4762 3 x M6 x 65 4762 9.0 32 0.2 0.7 1.8 +0.1 2.0 3 x M6 x 60 4762 3 x M6 x 70 4762 9.0 60 0.25 0.8 2.2 +0.1 2.0 3 x M8 x 75 4762 3 x M8 x 85 4762 22 100 0.3 0.9 2.2 +0.1 1.6 3 x M8 x 80 4762 3 x M8 x 90 4762 22 150 0.3 0.9 2.2 +0.1 1.6 3 x M8 x 100 4762 3 x M8 x 110 4762 22 250 0.35 0.95 2.4 +0.1 1.5 3 x M10 x 110 4762 3 x M10 x 130 4762 45 500 0.4 +0.2 1.0 2.4 +0.1 1.5 6 x M10 x 110 4762 6 x M10 x 130 4762 45 Table 3: Technical data (dependent on size) Size Hand release force [N] at 891.0/2 Release angle "" 891.1 [ ] Min. width of the counter friction surface Tightening torque shoulder screw Item 10 (Fig. 1) [mm] [Nm] 891. _.0 Through hole (coil carrier back) [mm] 891. _.1 891. _.2 2 20 26 6 5 0.5 16.5 Brake closed 23.5 H7 4 35 45 7 6 0.5 18 Brake closed 28.5 H7 8 70 90 7 6 1.5 22 22 H8 32.5 H7 16 100 125 7 7 2.0 33 22 H8 40.5 H7 32 130 170 8 8 2.0 36 28 H8 52.5 H7 60 220 300 10 8 3.5 38 32 H8 60 H7 100 260 340 12 10 8.0 48 42 H8 75.5 H7 150 290 350 13 12 8.0 55 48 H8 82.5 H7 250 350 430 10 14 18.5 65 52 H8 92 H7 500 310 470 10 19 18.5 85 62 H8 131 H7 Page 8 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Table 4: Technical data (dependent on size) Mass moment of inertia J Hub + rotor on d max [kgm 2 ] Friction work Q r 0.1 (per 0.1 mm wear) Valid for standard brakes type 891.0._ and 891.2._ Friction work Q r ges. (max. possible friction work related to nominal air gap) Rotor thickness New condition Minimum rotor thickness (limit value for braking torque 100 %) [J] [J] [mm] [mm] Size 891.0._ 891.2._ 2 0.12 x 10-4 0.1 x 10-4 35 x 10 6 95 x 10 6 6.05 5.8 4 0.21 x 10-4 0.17 x 10-4 40 x 10 6 100 x 10 6 6.05 5.8 8 0.67 x 10-4 0.58 x 10-4 65 x 10 6 162 x 10 6 6.9 6.65 16 1.74 x 10-4 1.53 x 10-4 100 x 10 6 500 x 10 6 8.0 7.5 32 4.48 x 10-4 4.1 x 10-4 130 x 10 6 600 x 10 6 10.4 9.9 60 6.74 x 10-4 110 x 10 6 590 x 10 6 11.15 10.6 100 16.54 x 10-4 140 x 10 6 840 x 10 6 14.0 13.4 150 31.68 x 10-4 120 x 10 6 720 x 10 6 15.5 14.9 250 61.82 x 10-4 130 x 10 6 780 x 10 6 17 16.4 500 222.6 x 10-4 170 x 10 6 1700 x 10 6 18.5 17.9 The stated values Q r 0.1 and Q r ges. are only reference values for specific friction work values < 0.5 J/mm 2 and sliding speeds < 10 m/s. Table 5: Technical data (dependent on size) Valid for holding brakes 891.1._ Mass moment of inertia J Hub + rotor on d max Friction work Q r 0.1 (per 0.1 mm wear) Friction work Q r ges. (max. possible friction work related to nominal air gap) Rotor thickness new Size [kgm2] [J] 2 0.12 x 10-4 7 x 10 6 7 x 10 6 6.05 4 0.21 x 10-4 8 x 10 6 8 x 10 6 6.05 8 0.67 x 10-4 13 x 10 6 13 x 10 6 6.9 16 1.74 x 10-4 20 x 10 6 20 x 10 6 8.0 32 4.48 x 10-4 30 x 10 6 45 x 10 6 10.4 60 6.74 x 10-4 50 x 10 6 100 x 10 6 11.15 100 16.54 x 10-4 60 x 10 6 144 x 10 6 14.0 150 31.68 x 10-4 40 x 10 6 160 x 10 6 15.5 250 61.82 x 10-4 50 x 10 6 220 x 10 6 17 500 222.6 x 10-4 70 x 10 6 350 x 10 6 18.5 [J] [mm] The stated values Q r 0.1 and Q r ges. are only reference values for specific friction work values < 0.5 J/mm 2 and sliding speeds < 10 m/s. Page 9 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Table 6: Technical Data (Dependent on Size) Size Permitted hub bores for standard brake 891.0._ und 891.2._ Permitted hub bores for holding brake 891.10 _._ Keyway JS9 Keyway P9 Keyway JS9 Keyway P9 DIN 6885/1 DIN 6885/3 DIN 6885/1 DIN 6885/3 DIN 6885/1 DIN 6885/3 DIN 6885/1 DIN 6885/3 2 8 13 13 15 8 13 13 15 8 13 13 15 8 13 13 15 4 10 13 13 15 10 13 13 15 10 13 13 15 10 13 13 15 8 11 18 18 20 11 18 18 20 11 18 18 20 11 18 18 20 16 14 22 22 25 14 20 20 22 14 22 22 25 14 20 20 22 32 19 30 19 28 28 30 19 30 19 28 28 30 60 22 32 32 35 22 32 22 32 32 35 22 32 100 24 42 42 45 24 42 42 45 24 42 42 45 24 42 42 45 150 30 45 45 50 30 45 45 50 30 45 45 50 30 45 45 50 250 40 2) 55 55 60 40 2) 50 50 55 40 55 40 50 50 55 500 50 2) 75 75 80 50 2) 75 75 80 50 75 50 75 2) Minimum bore not permitted for 891._8_._ Table 7: Technical data (dependent on size) Size 891._8_._ 891._7_._ Standard brake 891._1_._ Braking torque [Nm] with tolerance +40% / -20% 4) 891._2_._ 891._3_._ 891._4_._ 891._5_._ Holding brake 891.10_._ 2 2.5 2.2 2 1.7 1.4 1 0.7 4 4 5 4.5 4 3.4 2.8 2 1.4 8 8 10 9 8 6.8 5.5 4 2.8 16 16 20 18 16 13.5 11 8 5.5 32 32 40 36 32 27 22 16 11 64 60 75 68 60 50 41 30 21 100 100 125 110 100 85 70 50 180 150 210 180 150 125 100 75 280 250 360 290 250 215 180 125 460 500 700 3) 600 500 400 350 250 200 900 3) 3) Brake operation only possible with overexcitation. 4) For restricted braking torque tolerances please contact mayr power transmission. Design ROBA-stop -M brakes are spring applied, electromagnetic safety brakes, which apply a defined braking effect after the voltage is switched off or after a voltage failure. Function The ROBA-stop -M brake is a spring applied, electromagnetic safety brake. Spring applied function (brake): In de-energised condition, thrust springs (6) press against the armature disk (3). The rotor (4) is held between the armature disk (3) and the friction disk (5), the flange plate (12 or 13 / dependent on ) or the customer-side machine wall via frictional locking. The braking torque is introduced into the drive line via the toothing of the rotor (4) and the hub (1). Safety brake function: The ROBA-stop -M brake brakes reliably and safely in the event of a power switch-off, a power failure or an EMERGENCY STOP. Scope of Delivery / State of Delivery Please check the scope of delivery as well as the state of delivery immediately after receiving the goods. mayr will take no responsibility for belated complaints. Please report transport damage immediately to the deliverer. Please report incomplete delivery and obvious defects immediately to the manufacturer. Electromagnetic function (release): Due to the magnetic force of the coil in the coil carrier (2), the armature disk (3) is attracted against the spring pressure to the coil carrier (2). The brake is released and the brake rotor (4) with the hub (1) can rotate freely. Page 10 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Installation Conditions The eccentricity of the shaft end in relation to the mounting pitch circle must not exceed 0.2 mm. The positional tolerance of the threads for the cap screws (8) must not exceed 0.2 mm. The axial run-out deviation of the screw-on surface to the shaft must not exceed the permitted axial run-out tolerance of 0.08 mm for Sizes 2 to 8, of 0.1 mm for Sizes 16 to 250, and of 0.125 mm for Size 500, according to DIN 42955. The reference diameter is the pitch circle diameter for securement of the brakes. Larger deviations can lead to a drop in torque, to continuous grinding of the rotor (4) and to overheating. The tolerances of the hub bore (1) and the shaft must be selected so that the hub toothing (1) is not widened. Widening of the toothing leads to the rotor (4) jamming on the hub (1) and therefore to brake malfunctions. Recommended hub shaft tolerance H7/k6. The max. permitted joining temperature of 200 C must not be exceeded. The rotor (4) and brake surfaces must be oil and greasefree. A suitable counter friction surface (steel or cast iron) must be used. Sharp-edged interruptions on the friction surfaces must be avoided. For holding brakes: (Task: Holding application with EMERGENCY STOP function) For dynamic applications: (Task: Frequent dynamic braking) Surface quality in the friction area of the friction surface between Ra = 1.6 µm up to Ra = 3.2 µm Surface quality in the friction area of the friction surface Ra = 1.6 µm. Protect the rotor from rusting up / seizing up against the bearing shield / the flange plate (customer-side). We recommend tried and tested anti-corrosion measures for the mounting surface: dry, oil-free phosphate layers Hard chromium and nitriding Run-in Procedure Please carry out conditioning of the friction lining pairing before initial operation of the system (see Run-in procedure / Conditioning of the friction lining pairing, page 6) Installation (Figs. 1 and 2) 5.1. Mount the hub (1) onto the shaft, bring it into the correct position and secure it axially (e.g. using a locking ring). 5.2. If necessary (dependent on ), insert the O-ring (11) into the axial groove of the flange plate (12). 5.3. If necessary (dependent on ), guide the friction disk (5) or flange plate (12/13) over the shaft and attach it to the machine wall (observe the bore alignments in the friction disk (5) or flange plate (12/13) to the threaded bores in the machine wall). In the delivery of Sizes 150 and 250, three additional (shorter) cap screws are included in addition to the fixing screws (8). These additional screws must only be used for attaching the flange plate (12/13) by the customer, when personal protection acc. to the B 10d value is required. For this, 3 stepped bores can be found in the flange plates. Tightening torque like Item 8 of the respective Size acc. Table 3. Attention! When machining grey cast iron, please make sure that the cast tips are removed. The toothings of the hub (1) and the rotor (3) must not be oiled or greased. Friction value-increasing surface treatments are not permitted. Dimensioning of the key connection according to the requirements shaft diameter, transmittable torque and operating conditions must be carried out. For this, the corresponding user data must be known or the customer must carry out the dimensioning according to the valid calculation basis DIN 6892. For the calculation, a hub quality of Re = 230 N/mm 2 should be used for Sizes 2 and 4 and of Re = 300 N/mm 2 should be used for Sizes 8 to 500. The length of the key should lie over the entire hub. For the dimensioning of the key connections, the permitted tensions common in machine construction must be considered. During initial operation, check whether the key is inserted correctly and whether the brake is secured to the correct tightening torque acc. Table 2. Please abstain from using cleaning agents containing solvents, as they could affect the friction material. 5.4. Measure the rotor thickness and compare with the values in Tables 4/5. Push the rotor (4) onto the hub (1) by hand (the rotor collar should be facing away from the machine wall or friction disk (5) or flange plate (12/13)). The rotor toothing must lie over the entire length of the hub (1). Make sure that the toothing moves easily. Do not cause any damage! 5.5. If necessary, install the hand release acc. section 8 on page 12. 5.6. If necessary (dependent on ), insert the O-ring (11) into the axial groove of the coil carrier (2). 5.7. Push the rest of the brake over the hub (1) and the rotor collar (4) (the fixing holes should align with the bores on the friction disk (5), the flange plate (12/13) or the machine wall). The shoulder screws (10) prevent the individual components from falling apart. They do not affect the brake function and must not be removed during installation. 5.8. Secure the brake evenly all around using the cap screws (8) inc. the manufacturer-side mounted flat sealing rings (9 / dependent on ) with a torque wrench and a tightening torque (acc. Table 2). Page 11 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Braking torque adjustment The ROBA-stop -M brakes are set manufacturer-side to the braking torque stipulated on order. Different braking torque adjustments can be made using different spring configurations (6) in the coil carrier (2) (see Table 7). The respective thrust spring set (6) for the requested braking torque adjustment (acc. Table 7) is to be installed at the place of manufacture. If installation by the user is unavoidable, the required thrust spring set (6) must be ordered stating the exact construction size and braking torque adjustment values. Thrust Springs (6) Replacement: (Attention: The brake must be load-free) In order to replace the thrust springs (6), the brake must be unscrewed from the motor bearing shield or from the machine wall. 6.1. Remove the fixing screws (8). 6.2. Unscrew the shoulder screws (10) from the coil carrier (2) and remove the armature disk (3). CAUTION It is possible that the thrust springs relax suddenly. This might lead to internal and external bruising. The thrust springs (6) press against the armature disk (3). In order to remove the shoulder screws (10), the armature disk (3) must be pressed against the coil carrier (2), if necessary using an auxiliary tool, to avoid immediate relaxation of the thrust springs (6). Observe the installation position of the armature disk (3), or ensure that no thrust springs (6) fall out. 6.3. Replace the thrust springs (6). Attention: Insert the new thrust spring set (6) in symmetrical order. 6.4. Place the armature disk (3) onto the coil carrier (2) or the thrust springs (6) (observe installation position; use fixing screws (8) as a centring aid if necessary on Sizes 2 60). 6.5. Press the armature disk (3) down against the spring force and screw in the shoulder screws (10) up to their limits using a tightening torque acc. Table 3. 6.6. Screw the brake onto the motor bearing shield or the machine wall using fixing screws (8). (Please observe the tightening torque acc. Table 2). Hand Release Installation (see Figs. 1 and 5) For 891. _.1, installation of the hand release is only possible if a request for hand release is stated on the brake order form (completely enclosed coil carrier (2)). CAUTION For hand release installation, the brake must be dismantled and de-energised. Procedural Method: 8.1. Put the thrust springs (18) onto the threaded bolts (17). The threaded bolts (17) come manufacturer-side assembled with a key as tension element and secured with adhesive up to Size M60. This connection must not be loosened. 8.2. Push the threaded bolts (17) with thrust springs (18) from the inside (you should be facing the magnetic coil (7)) into the hand release bores in the coil carrier (2). 8.3. (Only on sealed hand release ( 891. _.1): Push the O-rings (21) over the threaded bolts (17) and insert them into the coil carrier (2) recesses. Avoid crushing the O-rings (21). 8.4. (Only on sealed hand release ( 891. _.1): Push the intermediate plates (22) over the threaded bolts (17). 8.5. Mount the switch bracket (16), add the washers (20) and lightly screw on the self-locking hexagon nuts (19). 8.6. Tighten both hexagon nuts (19) until the armature disk (3) lies evenly against the coil carrier (2). 8.7. Loosen both hexagon nuts (19) by "Y" turns (see Table 2), thereby producing an air gap between the armature disk (3) and the coil carrier (2). This gives you inspection dimension "x". CAUTION An uneven adjustment dimension on the hand release or incorrect adjustment can cause the brake to malfunction or the braking function to be lost. 8.8. After installing the release cover, screw the hand release rod (15) into the switch bracket (16) and tighten it. The hand release rod (15) must be secured against loosening using a screw-securing product, e.g. Loctite 243. 17 21 22 16 20 19 Y 7 Brake Inspection (before brake initial operation) 18 - Braking torque inspection: Please compare the requested braking torque with the torque stated on the tag (26). - Carry out a release inspection: by energising the brake or manually with the hand release (dependent on ). The braking torque is not achieved until after the run-in procedure has been carried out. 3 Inspection dimension "x" 2 See page 6 Definition of the braking torques. Fig. 5 The inspection dimension "x" (Fig. 5) is only used for hand release adjustment in dismantled condition. Page 12 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Switching Times M M M Br M Br M L M L t 11 t 1 t 2 0,1 x M Br t t 11 t 1 t 2 0,1 x M Br t U U U O t O U N U H t t Diagram 1 Diagram 2 Switching times for brake operation with coil nominal voltage Switching times for brake operation with overexcitation voltage Key M Br = Braking torque M L = Load torque t 1 = Connection time t 11 = Response delay on connection t 2 = Separation time t O = Overexcitation time U N = Coil nominal voltage U H = Holding voltage U O = Overexcitation voltage Table 8: Switching times Switching times 1) Size 2 4 8 16 32 60 100 150 250 500 Nominal torque 891._1_._ M2 [Nm] 2 4 8 16 32 60 100 150 250 500 Connection time DC-side switching t1 [ms] 10 18 20 30 50 55 68 80 100 100 AC-side switching t1 [ms] 100 160 220 320 400 500 640 730 1100 1100 Response delay on DC-side switching t11 [ms] 6 12 16 25 35 35 38 40 50 30 connection AC-side switching t11 [ms] 80 130 175 240 300 350 400 450 700 700 Separation time 2) t2 [ms] 33 36 54 84 120 180 216 264 348 480 Nominal torque 891._2_._ M2 [Nm] 1.7 3.4 6.8 13.5 27 51 85 125 215 400 Connection time DC-side switching t1 [ms] 16 29 32 48 80 88 109 128 160 160 AC-side switching t1 [ms] 160 256 352 512 640 800 1024 1168 1760 1760 Response delay on DC-side switching t11 [ms] 9.6 19 26 40 56 56 61 64 80 48 connection AC-side switching t11 [ms] 128 208 280 384 480 560 640 720 1120 1120 Separation time t2 [ms] 24 26 39 61 87 130 157 191 252 348 Nominal torque 891._3_._ M2 [Nm] 1.4 2.8 5.5 11 22 42 70 100 180 350 Connection time DC-side switching t1 [ms] 22 40 44 66 110 121 150 176 220 220 AC-side switching t1 [ms] 220 352 484 704 880 1100 1408 1606 2420 2420 Response delay on DC-side switching t11 [ms] 13 26 35 55 77 77 84 88 110 66 connection AC-side switching t11 [ms] 176 286 385 528 660 770 880 990 1540 1540 Separation time t2 [ms] 21 23 34 53 75 113 135 165 218 300 1) Standard brakes with braking torque adjustment 891._4_._ and 891._5_._ have significantly longer connection times t1 and must not be used for switching-time relevant applications. 2) The separation time t2 of holding brakes is 1.4 times longer than the separation time of standard brakes ( 891._1_._). 3) Value for operation with overexcitation Page 13 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Electrical Connection and Wiring DC current is necessary for operation of the brake. The coil voltage is indicated on the tag as well as on the brake body and is designed according to the DIN IEC 60038 (±10 % tolerance). Operation can take place with alternating voltage using a rectifier or another suitable DC power supply. The connection possibilities can vary dependent on the brake equipment. Please follow the exact connections according to the Wiring Diagram. The manufacturer and the user must observe the applicable regulations and standards (e.g. DIN EN 60204-1 and DIN VDE 0580). Their observance must be guaranteed and doublechecked! Earthing Connection The brake is designed for Protection Class I. This protection covers therefore not only the basic insulation, but also the connection of all conductive parts to the protective conductor (PE) on the fixed installation. If the basic insulation fails, no contact voltage will remain. Please carry out a standardised inspection of the protective conductor connections to all contactable metal parts! Device Fuses To protect against damage from short circuits, please add suitable device fuses to the mains cable. Switching Behaviour The reliable operational behaviour of a brake is to a large extent dependent on the switching mode used. Furthermore, the switching times are influenced by the temperature and the air gap between the armature disk and the coil carrier (dependent on the wear condition of the linings). Operation with overexcitation requires an inspection of: - the required overexcitation time* - as well as the RMS coil capacity** with a cycle frequency higher than 1 cycle per minute. * Overexcitation time t O Increased wear, and therefore an increasing air gap as well as coil heating lengthen the separation times t 2 for the brake. For this reason, at least double the separation time t 2 at nominal voltage must be selected as overexcitation time t O on each brake size. The spring forces also influence the brake separation times t 2: Higher spring forces increase the separation times t 2 and lower spring forces reduce the separation times t 2. The changes in the separation times t2 due to the spring configuration can be seen in the Diagram Separation time t2 of the brake dependent on the spring configuration. Spring force (braking torque adjustment) < 100 %: The overexcitation time t O is less than the doubled separation time t 2 on each brake size. Example: Spring configuration 891._5_._ => Separation time t 2 = 50 % --> Overexcitation time t O = 200 % x 50 % = 100 % t 2 Spring force (braking torque adjustment) = 100 %: The overexcitation time t O is the doubled separation time t 2 on each brake size. Spring force (braking torque adjustment) > 100 %: The overexcitation time t O is higher than the doubled separation time t 2 on each brake size. Example: Spring configuration 891._8_._ => Separation time t 2 = 120 % --> Overexcitation time t O = 200 % x 120 % = 240 % t 2 Magnetic Field Build-up When the voltage is switched on, a magnetic field is built up in the brake coil, which attracts the armature disk to the coil carrier and releases the brake. Field Build-up with Normal Excitation If the magnetic coil is energised with nominal voltage, the coil current does not immediately reach its nominal value. The coil inductivity causes the current to increase slowly as an exponential function. Accordingly, the build-up of the magnetic field takes place more slowly and the braking torque drop (curve 1) is also delayed. Field Build-up with Overexcitation A quicker drop in braking torque is achieved if the coil is temporarily placed under a higher voltage than the nominal voltage, as the current then increases more quickly. Once the brake is released, it needs to be switched over to the nominal voltage (curve 2). The relationship between overexcitation and separation time t 2 is roughly indirectly proportional, meaning that at doubled nominal voltage the separation time t 2 for release of the brake is halved. The ROBA -(multi)switch fast acting rectifier and phase demodulator work on this principle. I I O 2 M M Br I N 1 t 2 1 t Key and Calculations: P P N P O P H P P N The coil capacity P must not be larger than P N. Otherwise the coil may fail due to thermic overload. [W] RMS coil capacity dependent on switching frequency, overexcitation, reduction in capacity and duty cycle P = P O t O + P H t H T [W] Coil nominal capacity (catalogue values, tag) [W] Coil capacity on overexcitation P O = ( U 2 O ) P U N N [W] Coil capacity at reduced capacity P H = ( U 2 H ) P U N N t O [s] Overexcitation time t H [s] Time of operation with reduction in capacity t on [s] Time with voltage t off [s] Time without voltage T [s] Total time (t O + t H + t off) U O [V] Overexcitation voltage (bridge voltage) U H [V] Holding voltage (half-wave voltage) U N [V] Coil nominal voltage Page 14 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Time Diagram: U T Magnetic Field Removal AC-side Switching U O U = U H N 0 t O t on t H t off t S1 R ROBA -switch 20/017.000.2 U = 0,45 U~ 200-500V~ t: 0.05-2sec 200-300V~ R: 0Ω-10MΩ IN S DC OUT 1 2 3 4 5 6 7 8 I max = 1,8A + Coil R The power circuit is interrupted in front of the rectifier. The magnetic field slowly reduces. This delays the rise in braking torque. When switching times are not important, please switch ACside, as no protective measures are necessary for coil and switching contacts. Diagram: Separation time t 2 of the brake dependent on the spring configuration N F1 L F1: external fuse AC-side switching means low-noise switching; however, the brake engagement time is longer (approx. 6-10 times longer than with DC-side disconnection), use for non-critical braking times. DC-side Switching Separation time T2 [in %] S1 F1 R ROBA -switch 20/017.000.2 U = 0,45 U~ 200-500V~ t: 0.05-2sec 200-300V~ R: 0Ω-10MΩ IN S DC OUT 1 2 3 4 5 6 7 8 I max = 1,8A + Coil F1: external fuse R The power circuit is interrupted between the rectifier and the coil as well as mainsside. The magnetic field reduces extremely quickly. This causes a quick rise in braking torque. When switching DC-side, high voltage peaks are produced in the coil, which can lead to wear on the switching contacts from sparks and to destruction of the insulation. N L DC-side switching means short brake engagement times (e.g. for EMERGENCY STOP operation); however, louder switching noises. 891._X_._ Spring configuration Protection circuit When using DC-side switching, the coil must be protected by a suitable protection circuit according to VDE 0580, which is integrated in mayr -DC voltage modules. To protect the switching contact from consumption when using DC-side switching, additional protective measures are necessary (e.g. series connection of switching contacts). The switching contacts used should have a minimum contact opening of 3 mm and should be suitable for inductive load switching. Please make sure on selection that the rated voltage and the rated operating current are sufficient. Depending on the application, the switching contact can also be protected by other protection circuits (e.g. mayr -spark quenching unit, half-wave and bridge rectifiers), although this may of course then alter the switching times. Page 15 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Permitted Friction Work Qr [J] Permitted Friction Work Qr [J] Installation and Operational Instructions for Permitted Brake Friction Work The permitted friction work values dependent on the switching frequency shown in the characteristic curves must not be exceeded, not even in EMERGENCY STOP operation. The following diagrams show the permitted friction work values Qr referring to the respective switching frequency for the various brake sizes and rated speeds (Table 1). For 60 Hz operation, the max. permitted friction work values must be reduced to 70 %. Friction Power Diagram 1 for 891.01_._ and 891.21_._ (Standard brake) at reference speed nref (see Technical Data) Size 500 250 150 100 60 32 16 8 4 2 Switching Frequency 1/h Friction Power Diagram 2 for 891.01_._ and 891.21_._ (Standard brake) at Maximum speed nmax Size 500 250 150 100 60 32 16 8 4 2 Switching Frequency 1/h Page 16 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Friction Power Diagram 3 for 891.10_._ (Holding brake) at reference speed nref Permitted Friction Work Qr [J] Size 500 250 150 100 60 32 16 8 4 2 Switching Frequency 1/h Friction Power Diagram 4 for 891.10_._ (Holding brake) at Maximum speed nmax Size Permitted Friction Work Qr [J] 500 250 150 100 60 32 16 8 4 2 Switching Frequency 1/h Page 17 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner
Air Gap Inspection (only Size 500) The air gap can be inspected via a feeler gauge after removing the screw plug (A). The feeler gauge must be inserted at least 40 mm deep (see Fig. 6), so that the distance between the armature disk (3) and the coil carrier (2) can be measured. Feeler gauge We recommend the following regular inspection intervals: Once a year Inspection of the air gaps (brake in de-energised condition) Twice a year or after 1000 operating hours Inspection of the rotor thickness (wear) Inspection of the toothings of the rotor (4) and the hub (1) for moves easily, increased backlash and damage. min. 40 mm Sizes M2 M32 0.5 M60 M500 0.3 The max. permitted rotor torsional backlash on the hub Inspection on an engaged brake and load-free output by turning the motor shaft. Inspection of the armature disk (3) and the flange plate (12/13) or the friction surface of the motor plate for plane parallelism and wear (excessive scoring). Clean the brake Fig. 6 Maintenance The amount of wear on the rotor (4) must be examined during the regular inspection intervals: ROBA-stop -M brakes are mainly maintenance-free. The friction lining pairing is robust and wear-resistant. This ensures a particularly long service lifetime of the brake. The friction lining is subject to functional wear in case of EMER- GENCY STOP and during regular conditioning of the friction lining pairing. If the rotor (4) does become worn due to the high total friction work, and the function of the brake can no longer be guaranteed, the brake can be re-set to its functional state by replacing the rotor. The quality of the counter friction surface must be checked. The wear condition of the rotor (4) is determined by measuring the release voltage or the rotor thickness on a dismantled brake acc. Table 4/5. On size 500 there is an air gap inspection opening. This means that the heavy brake does not have to be dismantled. The release voltage may be up to max. 90 % of the nominal voltage on a warm brake. Wear Wear times are influenced by many factors and can vary substantially. The required inspection and maintenance intervals must be calculated individually according to the system manufacturer's planning documentation. Replacement of the rotor/ of the rotors after having reached the maximum air gap or In safety-critical applications (without cyclical brake test) at the latest after 6 years of operating the system Conditioning of the friction lining pairing during operation In order to maintain the brake torque in holding applications, the friction lining pairing must be conditioned regularly. This must be carried out in the form of dynamic braking procedures. Afterwards, the brake torque must be checked (see Run-in procedure / Conditioning of the friction lining pairing, page 6). Page 18 of 21 www.mayr.com, E-Mail: info@mayr.com your reliable partner